JP5651135B2 - Interior materials for vehicles - Google Patents

Description

  The present invention relates to a vehicular interior material, and more particularly to a vehicular interior material that is mounted on the inside of a roof of a vehicle.

  As this type of vehicle interior material, for example, as disclosed in Patent Document 1 below, a vehicle ceiling material in which a skin layer is provided on the front surface side of the base material and a back surface layer is provided on the back surface side of the base material is known. It has been.

  That is, as shown in FIG. 6, the vehicle interior material 10 includes a urethane base material 11, a front-side fiber layer 12 and a back-side fiber layer 13 disposed so as to sandwich the base material 11, and a surface The skin layer 14 provided on the surface of the side fiber layer 12 and forming the ceiling surface of the passenger compartment and the back surface layer 15 provided on the back surface of the back surface side fiber layer 13 are laminated.

  Here, the base material 11, the front surface side fiber layer 12, the back surface side fiber layer 13, and the skin layer 14 are made of an air permeable material, and the back surface layer 15 is made of an air permeable material. Thereby, the flow of air from the vehicle interior to the back surface side of the vehicle interior material 10 can be stopped, and dust is prevented from adhering to the surface of the skin layer 14.

  A method of manufacturing such a vehicle interior material 10 will be described with reference to FIG. In FIG. 7, the skin layer 14 is disposed on the upper side and the back surface layer 15 is disposed on the lower side in accordance with the direction of the molding material 10 ′.

  As shown in FIG. 7A, a base material 11, a front-side fiber layer 12, a back-side fiber layer 13, a skin layer 14, and a back-side layer 15 are laminated to prepare a molding material 10 '. An adhesive 17 is applied to the entire surface of the front-side fiber layer 12 and the back-side fiber layer 13 in advance in the molding material 10 ′. Then, as shown in FIG. 7B, hot press molding is performed with the molding material 10 ′ sandwiched between the upper mold 41 and the lower mold 42. At this time, the back surface of the skin layer 14 is bonded to the surface of the front surface side fiber layer 12, and the surface of the back surface layer 15 is bonded to the back surface of the back surface side fiber layer 13. Thereby, as shown in FIG. 6, all the layers are integrated and the vehicle interior material of a predetermined shape is obtained.

  Moreover, as another prior art relevant to this invention, there exists the following patent document 2, for example. Patent Document 2 is composed of a base material (base material) composed of a core material of a resin foam material and a covering material (skin layer) laminated on the indoor side of the core material, and an infrared reflective layer, and the infrared reflective layer is an automobile body. An automotive interior material is disclosed which is attached to a roof panel and the infrared reflective layer is made of, for example, an aluminum vapor deposition sheet so that heat is shielded by the aluminum vapor deposition sheet even when sunlight enters the roof panel. ing. Here, the aluminum vapor deposition sheet has a description that aluminum is vapor-deposited on a base material such as plastic.

JP 2003-280666 A Japanese Patent Laid-Open No. 2001-158306

  Here, the inventors of the present application tried to use, for example, an aluminum vapor deposited film instead of the back surface layer shown in Patent Document 1 or the infrared reflective layer shown in Patent Document 2.

  Here, two types of aluminum vapor deposition films are commercially available. One of them is called a single aluminum vapor deposition film. As shown in FIG. 8A, the aluminum vapor deposition film 1 has an aluminum vapor deposition layer 3 formed on the surface of a base film 2 made of resin. The film 2 and the aluminum vapor deposition layer 3 are configured by being firmly bonded by a special process. In FIG. 8A, the specially processed layer is denoted by reference numeral 4. The aluminum vapor deposition film 1 configured in this manner has an infrared reflectance of about 95% due to the aluminum vapor deposition layer, and has good infrared reflection efficiency.

  Another one of the aluminum vapor deposition films is a general aluminum vapor deposition film. As shown in FIG. 9A, the aluminum vapor deposition film 1 ′ has an aluminum vapor deposition layer in the configuration shown in FIG. A protective film 6 made of a resin is attached to the surface 3 with an adhesive 5 interposed. The general aluminum vapor-deposited film 1 ′ configured as described above has excellent durability of the aluminum vapor-deposited layer 3 because the protective film 6 is formed on the surface of the aluminum vapor-deposited layer 3.

  However, when the aluminum vapor-deposited film 1 having the structure shown in FIG. 8 (a) is incorporated into the vehicle interior material, the aluminum vapor-deposited layer 3 of the aluminum vapor-deposited film 1 is hydroxylated as shown in FIG. 8 (b). In order to avoid this, it is conceivable to arrange the aluminum vapor-deposited layer 3 toward the back side fiber layer 13 side, but from the skin layer 14, the front side fiber layer 12, the substrate 11, the back side fiber layer 13 and the like. It was found that due to the intrusion of moisture, the aluminum vapor deposition layer 3 was hydroxylated in a range of about 10% of the entire area, and the infrared reflectance of the aluminum vapor deposition layer 3 was reduced to about 60%. . Further, since infrared rays are incident and reflected through the base film 2 formed on the aluminum vapor-deposited film 1, the infrared reflectance is reduced to about 90%.

  Further, when the aluminum vapor-deposited film 1 ′ having the configuration shown in FIG. 9A is incorporated in the vehicle interior material, the base film 2 of the aluminum vapor-deposited film 1 ′ is formed on the back side fiber as shown in FIG. 9B. Although it adheres toward the layer 13 side, while aluminum vapor deposition film 1 'itself is expensive, the problem that a moldability is not favorable arises. Further, since infrared rays are incident and reflected through the protective film 6 formed on the aluminum vapor-deposited film 1 ', the infrared reflectance is reduced to about 90%.

  The present invention has been made based on such circumstances, and an object thereof is to provide an interior material for a vehicle that is inexpensive, has good moldability, and has high infrared reflectance.

  In order to achieve such an object, according to the present invention, a relatively inexpensive film in which an aluminum vapor deposition layer is formed on each of the front and back surfaces of a transparent base film is used as the aluminum vapor deposition film. .

  And the interior material for vehicles incorporating such an aluminum vapor deposition film is comprised with the moldability which can adhere | attach one of the aluminum vapor deposition layers formed in each of the front and back of a base film to the back surface side fiber layer 13, for example. Will be.

  In addition, one aluminum vapor deposition layer bonded to the back surface side fiber layer 13 undergoes hydroxylation due to intrusion of moisture from the back surface side fiber layer 13 or the like, and the other aluminum vapor deposition layer exposed to the outside air is also hydroxylated. Although it progresses, it will be provided with two infrared reflecting layers, so that it is possible to obtain a vehicle interior material having a high infrared reflectance even when compared with either configuration of FIG. 8B and FIG. 9B. Can do.

  In addition, the above-mentioned aluminum vapor deposition film is not necessarily limited to what vapor-deposited aluminum, For example, it can apply also when using the metal vapor deposition film which vapor-deposited other metals, such as chromium.

The present invention is grasped by the following composition.
(1) The vehicle interior material of the present invention includes a base material made of a foam member, a first fiber layer disposed on one surface of the base material so as to sandwich the base material, and the first fiber layer. A breathable skin layer provided on the surface of the substrate on the surface, a second fiber layer disposed on the other surface of the substrate, and bonded to the second fiber layer; and aluminum-deposited film to be provided on the vehicle body side of the wood, a vehicle interior material having a laminated structure of the first fiber layer and said second fibrous layer reinforces at least the vehicle interior material reinforcement The aluminum vapor-deposited film has a function of reflecting infrared rays and a non-breathable function, and a first aluminum vapor-deposited layer of a metal layer is formed on the surface of the base film made of a transparent resin . is composed of a second aluminum deposition layer of a metal layer on the back surface, the base fill And between the first aluminum deposition layer on its surface, and between the base film and the second aluminum deposition layer of the back surface, respectively, corona treatment or anchor coat treatment to adhere firmly it is applied The first aluminum is further provided with a special treatment layer, which is exposed to outside air on the surface side of the base film, and the first aluminum vapor deposition layer is hydroxylated by reacting with moisture in the air. Infrared reflectance with respect to infrared rays incident on the vapor deposition layer, and on the back side of the base film, the second aluminum vapor deposition layer comprises the skin layer, the first fiber layer, the base material, and the second fiber. Infrared reflectance for infrared rays incident on the second aluminum deposition layer due to partial hydroxylation by moisture entering from the layer is approximately the same, approximately 60 percent each. Toss .

  According to the vehicle interior material configured as described above, it is possible to obtain a vehicle interior material that is inexpensive, has good moldability, and has high infrared reflectance.

It is sectional drawing which shows the layer structure of Embodiment 1 of the vehicle interior material of this invention. It is the figure which showed the vehicle to which the interior material for vehicles of this invention is applied. It is the top view which looked at the vehicle interior material of this invention from the arrow C direction of FIG. It is sectional drawing which shows the manufacturing method of Embodiment 1 of the vehicle interior material of this invention. It is explanatory drawing which shows the optical path of the incident / reflection of the infrared rays of the vehicle interior material of this invention. It is sectional drawing which shows the layer structure of the conventional vehicle interior material. It is sectional drawing which shows one Example of the manufacturing method of the conventional vehicle interior material. It is sectional drawing which shows an example of the conventional aluminum vapor deposition film, and sectional drawing at the time of applying this aluminum vapor deposition film to the interior material for vehicles. It is sectional drawing which shows the other example of the conventional aluminum vapor deposition film, and sectional drawing at the time of applying this aluminum vapor deposition film to the interior material for vehicles.

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as embodiments) will be described in detail with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment.
(Embodiment 1)
FIG. 2 shows a vehicle to which the vehicle interior material 10 of the present invention is applied. As shown in FIG. 2, the vehicle 20 includes a vehicle body 21, a front wheel 22, a rear wheel 23, and a vehicle compartment 24. The vehicle interior material 10 is provided, for example, inside a loop 25 that covers the upper part of the vehicle compartment 24, and the vehicle interior material 10 is used to interior the ceiling surface of the vehicle interior 24.

  FIG. 3 is a plan view of the vehicle interior material 10 as viewed from the direction of arrow C in FIG. The front portion 301 is formed in a substantially flat plate shape, and a curved portion 302 is formed in the rear portion from the front portion 301 so as to increase toward the center. The vehicle interior material 10 is provided with, for example, an opening 303A for attaching an indoor lamp (room lamp, map lamp, etc.), an opening 303B for attaching a sun visor, and an opening 303C for attaching a grip. .

  FIG. 1 is a cross-sectional view showing a layer structure of a vehicle interior material 10. As shown in FIG. 1, the vehicle interior material 10 includes a base material 11, a front surface side fiber layer 12 and a back surface side fiber layer 13 disposed so as to sandwich the base material 11, and a front surface side fiber layer 12. The laminated structure of the skin layer 14 which is provided in the surface and forms the ceiling surface of a vehicle interior, and the aluminum vapor deposition film 30 adhere | attached on the surface of the back surface side fiber layer 13 is provided. Here, the aluminum vapor deposition film 30 is formed with aluminum vapor deposition layers 32 and 33 on the front and back surfaces of the base film 31 made of resin, and the base film 31 and these aluminum vapor deposition layers 32 and 33 are specially treated (for example, corona treatment or Strong adhesion is made by the anchor coat). In FIG. 1, the specially processed layers are denoted by reference numerals 34 and 35. Here, the base film 31 is formed of a transparent resin (for example, PP, PET, etc.), and a thickness in the range of 0.8 to 25 μm is appropriate. Moreover, the thickness of each aluminum vapor deposition layer 32 and 33 in the range of 0.01-0.09 micrometer is suitable. In addition, the adhesive agent 17 is apply | coated to the front and back of each of the surface side fiber layer 12 and the back surface side fiber layer 13 over the whole surface previously. Moreover, in FIG. 1, according to the position of each layer in a manufacturing process, the skin layer 14 is arrange | positioned at the upper rank, and the aluminum vapor deposition film 30 is arrange | positioned at the lower rank.

  In addition, the base material 11 is comprised from foam materials, such as a semi-rigid urethane foam, for example. The front surface side fiber layer 12 and the back surface side fiber layer 13 are made of a fiber material such as a glass mat. As described above, the front-side fiber layer 12 and the back-side fiber layer 13 are coated with the adhesive 17 over the entire front and back surfaces. The front-side fiber layer 12 and the back-side fiber layer 13 are reinforcing layers that reinforce the vehicle interior material 10 and also function as adhesive layers that adhere the skin layer 14 and the aluminum vapor-deposited film 30 to the substrate 11 side. . The skin layer 14 is arbitrarily selected from a breathable material such as unseen cloth, sanitary cloth, and knit. Moreover, the aluminum vapor deposition film 30 comprised in this way comes to have a non-breathable function besides the function to reflect infrared rays. As the adhesive 17, a moisture curable adhesive such as isocyanate or a thermosetting resin adhesive is suitable. Here, the adhesive 17 is applied to the front surface side fiber layer 12 and the back surface side fiber layer 13 to bond the skin layer 14 and the aluminum vapor deposition film 30, but the adhesive applied or impregnated to the base material 11 is used. The agent 17 is infiltrated into the front surface side fiber layer 12 and the back surface side fiber layer 13, and is adhered to the adhesive 17 on the front surface of the front surface side fiber layer 12 and the back surface of the back surface side fiber layer 13. You may make it adhere | attach the skin layer 14 and the aluminum vapor deposition film 30 to the layer 12 and the back surface side fiber layer 13, respectively.

Next, a method for manufacturing the vehicle interior material 10 as described above will be described with reference to FIG. The manufacturing method of the vehicle interior material 10 includes a material preparation process for obtaining a molding material 10 ′ and a molding process for performing hot press molding using the molding material 10 ′. As shown in FIG. 4A, in the material preparation step, the molding material 10 ′ is formed by laminating the base material 11, the front surface side fiber layer 12, the back surface side fiber layer 13, the skin layer 14, and the aluminum vapor deposition film 30. obtain. Then, the molding material 10 ′ is conveyed to the molding die 40 and set. Further, in the molding step, as shown in FIG. 4B, an upper mold 41 is formed using an upper mold 41 for molding the skin layer 14 side and a lower mold 42 for molding the aluminum vapor deposition film 30 side. And the lower mold 42 are clamped together, and the molding material 10 ′ is sandwiched between the upper mold 41 and the lower mold 42 to perform hot pressing at a mold temperature of 130 to 150 ° C. 4A and 4B, in the aluminum vapor deposition film 30, 35 is interposed between the base film 31 and the aluminum vapor deposition layer 33, and 34 is interposed between the base film 31 and the aluminum vapor deposition layer 32. Is omitted.
FIG. 5 is a cross-sectional view showing the vehicle interior material 10 formed as described above, and shows the aluminum vapor deposition film 30 positioned at the top. An arrow A in the figure indicates an optical path through which infrared rays are incident and reflected on the aluminum vapor deposition film 33 of the aluminum vapor deposition film 30, and an arrow B in the figure indicates an optical path through which infrared rays enter and reflect on the aluminum vapor deposition film 32 of the aluminum vapor deposition film 30. Yes.

  Although the aluminum vapor deposition film 32 of the aluminum vapor deposition film 30 is exposed to the outside air and cannot be prevented from proceeding with hydroxylation, the decrease in infrared reflectance due to the hydroxylation can be suppressed to about 30%. The reflectance can be maintained at about 60%. Moreover, the aluminum vapor deposition film 33 of the aluminum vapor deposition film 30 is hydroxylated in a range of about 10% of the entire area due to intrusion of moisture from the skin layer 14, the front surface side fiber layer 12, the base material 11, the back side fiber layer 13, and the like. However, the infrared reflectance of the aluminum vapor deposition layer 3 can be maintained at about 60%.

  From this, by forming the aluminum vapor deposition film 32 and the aluminum vapor deposition film 33 on the front and back surfaces of the aluminum vapor deposition film 30, for example, the aluminum vapor deposition is more than the configuration shown in FIG. 8B or FIG. 9B. The infrared reflectance of the film 30 can be greatly improved.

Therefore, it is possible to obtain the vehicle interior material 10 that is inexpensive, has good moldability, and has high infrared reflectance.
(Embodiment 2)
In the first embodiment, the front-side fiber layer 12 and the back-side fiber layer 13 are bonded to the front and back surfaces of the substrate 11, respectively. However, it goes without saying that these are not fiber layers, and may be other materials made of resin, for example.
(Embodiment 3)
In Embodiment 1, an aluminum vapor deposition film is used as the infrared reflecting layer. However, it is needless to say that the vapor deposition layer is not necessarily limited to aluminum, and may be a vapor deposition layer made of another metal such as chromium.

  As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the description of the scope of claims that embodiments with such changes or improvements can also be included in the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 1, 1 ', 30 ... Aluminum vapor deposition film, 3 ... Aluminum vapor deposition layer, 5 ... Adhesive, 6 ... Protective film, 10 ... Interior material for vehicles, 11 ... Base material, 12 ... Surface side Fiber layer, 13 ... Back side fiber layer, 14 ... Skin layer, 15 ... Back layer, 20 ... Vehicle, 21 ... Body, 22 ... Front wheel, 23 ... Rear wheel, 24 ... Car compartment, 25 ... Loop, 31 ... Base film, 32, 33 ... Aluminum vapor deposition layer.

Claims (1)

A base material made of a foam member;
A first fiber layer disposed on one surface of the substrate so as to sandwich the substrate;
A breathable skin layer provided on the vehicle side of the base material on the surface of the first fiber layer ;
A second fiber layer disposed on the other surface of the substrate ;
Is bonded to said second fiber layer, and the aluminum deposition film to be provided on the vehicle body side of the substrate, a vehicle interior material having a layered structure,
The first fiber layer and the second fiber layer are reinforcement layers that reinforce at least the vehicle interior material,
The aluminum vapor-deposited film has a function of reflecting infrared rays and a non-breathable function. The first aluminum vapor-deposited layer of the metal layer is formed on the surface of the base film made of a transparent resin, and the metal layer is formed on the rear surface of the base film. A second aluminum vapor deposition layer,
Between the first aluminum deposition layer of the base film and the surface, and between the base film and the second aluminum deposition layer of the back surface, respectively, is a corona treatment or anchor coat treatment to adhere firmly Further having a special treatment layer applied,
The first aluminum vapor deposition layer is exposed to the outside air on the surface side of the base film, and the first aluminum vapor deposition layer reacts with moisture in the air to be hydroxylated. Infrared reflectance,
On the back side of the base film, the second aluminum vapor deposition layer is partially hydroxylated by moisture entering from the skin layer, the first fiber layer, the base material, and the second fiber layer. Thus, the interior reflectance for a vehicle, characterized in that the infrared reflectance with respect to the infrared light incident on the second aluminum vapor deposition layer is substantially the same, and is approximately 60% of each .

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